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Tat Plant

Tat tomato products are described as "perfect" by the consumers with their colors, smells and tastes. This is due to the understanding of quality of Tat in the process that starts from the field and continues up to the shelves and even up into the kitchens. Tat never makes concessions from quality as a producer with access to large masses in both Turkey and in the world market. Tat Gıda Sanayi A.Ş. Mustafakemalpaşa factory established the HACCP system in 1996 and received ISO 9001 KYS certification in the same year. These systems are still implemented and they are verified and updated periodically through second and third party audits along with internal audits. As a necessity of these systems, our company has documented production procedures, process flow charts, process details, quality plans, final product specifications, specifications for raw materials and auxiliary materials, maintenance plans and equipment calibrations along with HACCP plans, verification activities, GMPs, and systems for call back and traceability. The responsibilities relating to such activities have also been documented and set out in the job definitions. The same approach is adopted for the production of all the products in our company and in additionally, customer requirements are also taken into consideration.

1. Paste:
Tomatoes harvested from the field are brought to the plant by trailers or trucks. During entrance to the plant, controls take place at Entrance Quality Control Station. The tomatoes with proper quality are accepted and are dispatched to stocking area by trailers and trucks to keep them on hold. The trailers and trucks in line are dispatched down to the tomato lowering basins and lowering takes place by the help of water. The tomatoes fed to the plant therefrom are subjected to sorting and washing and are chopped. Then, the chopped tomatoes are subjected to preliminary heating for enzyme activation. The heat applied here is between 60 – 95 ° C. As the temperature applied during preliminary heating goes up, the fluidity of the paste is reduced, such paste is defined as HB and is used mostly for the production of Ketchup. As the temperature of the preliminary heating goes down, the paste to be obtained becomes more fluid, and such paste is described as CB paste, which is more suitable for use in the production of sauces - tomato juice and for use in kitchen. The preliminary temperature applied for the paste produced as HB is 75 to 95 ° C, while the preliminary temperature applied for the paste produced as CB is 60 to 75 ° C.

The chopped tomatoes with preliminary heating process completed are later sieved, removing the skin and pips and obtaining tomato juice. The diameter of the sieve holes used is picked according to the nature of the paste intended. If a rough textured paste is desired, the sieve hole diameter goes larger and for a finer textured paste, it does narrower. In the production of standard paste, sieves with hole diameter of 0,6 – 0,8 mm are used. The tomato juice obtained is accumulated in tomato juice collection tanks and is fed to the evaporators, where thickening process takes place. Here, the dry matter content is enhanced by boiling under vacuum until the desired value is reached. The dry matter content (Brix) of the normal paste sold at shops is 28/30. In industrial use, this value can be set as higher or lower depending on the request of the customer. During recent years, the shops also sell thick paste with Brix up to 36/38.

Following evaporation process, the paste obtained is packed. Cans and glass jars produced for normal domestic use are hot filled following pasteurization (92 – 96 ° C) and sealed hermetically. Then the paste is routed through pasteurization and cooling tunnels in the form of open tunnels, thus pasteurized finally and cooled, and is packed and delivered to the storage. Dispatch takes place from the storage depending on the order status.

There is aseptic filling technology for industrial production. For production with this technique, paste is heated to 110 – 112 ° C and sterilized and then cooled down to 30 – 35 ° C and filled in aseptic bags. Aseptic productions can be in special packing such as drums of 220 – 250 kg or special cage packing of 1.300 – 1.400 kg.

2. Canned vegetables:
The vegetables brought to the plant following harvest are first subjected to processes for sorting, sorting granules, cutting-sizing etc. After such processes are complete, the vegetables are boiled at 85 to 95 ° C depending on the nature of the vegetable for 3 to 5 minutes and then cooled in cooling drums. Then the final sorting takes place and filling is made. During filling stage, first the can or the jar is filled with vegetables and then with hot brine (salty water) and the lids are sealed. Then, following sterilization for 15 to 30 minutes at 110 to 121 °C depending on the vegetable of the nature in pressurized containers named autoclave, they are cooled. The cans cooled are packed and delivered to the storage. Dispatch takes place from the storage depending on the order status.

3. Boiled products:
The technology for boiled products is very similar to the can processing technology. Dry legumes are kept in water for a certain period at the start of the process for preliminary swelling. Then they are boiled at 90 - 95 ° C for 5 to 10 minutes depending on the variety of the legume and cooled. Then the filling takes place following final sorting. At the filling stage, first the cans or the jars are filled with the legumes, followed by brine (salty water) and the lids are sealed. Then, following sterilization at 110 to 121 °C for 20 to 30 minutes -depending on the type of the legume- in pressurized containers named autoclave, cooling takes place. Then the cooled boiled products are packed and delivered to the storage. Dispatch takes place from the storage depending on the order status. As such products are ready-to-cook products, they facilitate kitchen work, and therefore the demand for them goes up day by day.

4. Ready to serve meals:
The technology for the ready to serve meals is one that is similar to the technology for boiled products. Here, especially red kidney beans in olive oil (barbunya pilaki), beans in olive oil (fasulye pilaki) and stuffed vine leaves (yaprak sarma) are in demand in the market. In the production of red kidney beans in olive oil, the dry red kidney beans are kept in water for a specific period at the start of the process, allowing preliminary swelling. Then they are boiled in 90 to 95 ° C for 10 to 12 minutes, followed by cooling in cooling drums. Then, following final sorting, they are mixed with tomato and tomatoes and roasted onions and filled. At the filling stage, the can is filled with red kidney beans first, special sauce and vegetable oil next and the lids are sealed. Then, following sterilization in pressurized containers named autoclave at 120 - 125 °C for 20  to 30 minutes, colling takes place. After cooling, the red kidney beans are packed and delivered to the storage. Dispatch takes place from the storage depending on the order status. Beans in olive oil are also produced in the same manner. During production of stuffed vine leaves, first the stuffing is prepared with rice, onions and natural spices and the vine leaves are stuffed with this stuffing prepared. Production of stuffed vine leaves is a very labor intense production in this respect. The prepared stuffed vine leaves are placed in cans and topped with brine (salty water) and vegetable oil and the lids are sealed. Then, following sterilization at 120 to 125 °C for 20 to 30 minutes in pressurized containers named autoclave, cooling takes place. Then the cooled stuffed vine leaves are packed and delivered to the storage. Dispatch takes place from the storage depending on the order status.

5. Jam:

Fresh, frozen or dried fruits are used for producing jam. Although it is always more advantageous to work on fresh fruits in terms of cost, it is necessary to produce a certain quantity using frozen or dried fruits due to insufficient harvest season. At the stage of production from fresh fruits, the harvested fruits undergo processes of sorting by varieties, removing the skins, removing the pips, cutting/chopping after they arrive at the plant. If frozen raw materials are used, these stages take place in advance. If dried fruits are used, the fruits are kept in water first, followed by sorting, cutting etc. Then sugar, glucose and fruits are mixed in special machinery operating under vacuum, allowing the mixture to get dense. In the last stage of the operation, vacuum is removed and the temperature is taken to 90 – 95 ° C. In the production of jam, sugar and glucose should absolutely be used together. Otherwise, crystallization problem known as granulation may occur in time.

6. Pickles:
There are two types of pickles: fermented or pasteurized. Pasteurized type of pickles are filled in jars following sorting the raw materials and preliminary preparations and then the brine containing salt and vinegar is added. Then these pickles are passed through pasteurized tunnels and cooled. Later, the cooled pickles are packed and delivered to the storage. Dispatch takes place from the storage depending on the order status. For fermented pickles, on the other hand, the raw materials are taken to large drums or tanks following preliminary preparations and sorting, and first fermentation is completed, just like the pickles we prepare at home. The pickles with complete fermentation are filled in jars and added new brine and pasteurized, followed by cooling. Then the cooled pickles are packed and delivered to the storage. Dispatch takes place from the storage depending on the order status.

7. Tomato Juice:
The tomato-derivative products are products that are proven to enhance the strength of the body against cancer due to the lycopene, the coloring agent they naturally contain. Tomato juice consumption is very high especially in economically developed countries. And our country needs to increase tomato juice consumption. Tomato juice is produced using tomato paste. Paste especially produced for this purpose should be used. The paste to be used in tomato juice production should have high fluidity and should have a bright red color. Tomato juice can also be used as a drink. Moreover, tomato soup or sauce for baked meals can be made from this product.

8. Ketchup:
It is prepared by mixing tomato paste, sugar, salt, vinegar and special spices according to a certain formulation. Then it is pasteurized at 95 – 105 ° C, cooled down to 70 – 80 ° C and subjected to stages of deaeration and homogenization in order, respectively. The prepared ketchup is filled in the desired packing and is cooled. Then labeling, packing stages are completed and it is delivered to the storage as ready for dispatch.

9. Mayonnaise:
In producing mayonnaise, sunflower oil, pasteurized liquid egg, sugar, salt, vinegar and special spices are used. Emulsion is created through homogenization in special mixers working under vacuum and it is filled in desired packing without any thermal process. Then labeling, packing stages are completed and it is delivered to the storage as ready for dispatch.

Tat Karacabey Plant
Address : Okçugüzel Yolu Üzeri, Hotalı Köyü
Civarı PK:362 Karacabey / Bursa
Phone : 0 224 646 15 64 – 3 Hat
Fax : 0 224 676 09 09 
Web : www.tat.com.tr
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Tat
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